Components produced from metallic blanks and methods for producing the same

Abstract

Components, methods for producing the components from metallic blanks, and vehicles comprising the components are provided. The components include a body having protrusions and recesses formed by a process including forming the component from a metallic blank by a drawing or stamping process. The metallic blank has at least one notch along a perimeter thereof that is configured to reduce elastic strain retained in the component formed therefrom. The at least one notch provides for relaxation of elastic strain within the component during the drawing or stamping process and thereby reduces springback distortion of the component.

What is claimed is: 
     
       1. A method, comprising:
 determining a location of an area of concentrated total strain based on a structure of a component to be produced prior to forming the component, the component including elongated protrusions, wherein the area of concentrated total strain includes elastic strain trapped by plastic strain caused by the elongated protrusions, wherein the trapped elastic strain is sufficient to cause springback and/or unstable physical distortion of the component subsequent to production thereof upon release of forces applied during a drawing or stamping process; 
 forming at least one notch along a perimeter of a metallic blank that is configured to be used to produce the component based at least in part on the location of the area of concentrated total strain, wherein the at least one notch is configured to reduce the elastic strain trapped in the component during and/or subsequent to the drawing or stamping process; and 
 producing the component from the metallic blank by the drawing or stamping process, wherein the at least one notch provides for relaxation of the elastic strain trapped within the component during the drawing or stamping process and thereby reduces distortion of the component subsequent to completion of the drawing or stamping process upon release of the forces applied during the drawing or stamping process. 
 
     
     
       2. The method of  claim 1 , wherein the at least one notch is formed in the metallic blank prior to producing the component therefrom. 
     
     
       3. The method of  claim 2 , further comprising:
 generating a strain map for the component, wherein determining the location of the area of concentrated total strain is performed, at least in part, using the strain map; and 
 determining a size, shape, and location of the at least one notch, at least in part, using computational modeling. 
 
     
     
       4. The method of  claim 1 , further comprising forming the at least one notch at a corner of the metallic blank. 
     
     
       5. The method of  claim 1 , further comprising forming the at least one notch along a side edge of the metallic blank between a pair of corners thereof. 
     
     
       6. The method of  claim 1 , further comprising forming the at least one notch to define a gap in a sidewall of the component. 
     
     
       7. The method of  claim 1 , wherein the metallic blank is formed of a mild, medium, high strength, or third generation (3rd Gen or Gen3) advanced high-strength (AHSS) steels, or an aluminum alloy. 
     
     
       8. The method of  claim 1 , wherein the component is configured to be installed as a structural component of a vehicle.